Generac Power Systems 004451 ,004582 manual

FOR YOUR NEAREST AUTHORIZED SER VICE CENTER 1-800-333-1322 Owner’s Manual U U L L T T R R A A S S O O U U R R C C E E Commer cial, Industrial, Residential P or table Generator MODELS: 004451 (12,500 W att) 004582 (15,000 W att) • Safety • Assembl y • Operation • Maintenance • T r oub leshooting • Electrical Data • P ar ts • W arra[...]

T able of Contents Commercial-Industrial-Residential P ortable Generator System Safety Rules ..............................................1-3 Section 1 – General Information ................4 1.1 Unpacking ............................................................................4 1.1.1 Accessor y Bo x .........................................[...]

INTR ODUCTION Thank you f or purchasing this model of the GU ARDIAN ® product line by Generac P ow er Systems, Inc. This model is a compact, high perf or mance, air-cooled, engine driven gener ator designed to supply electrical power to operate electrical loads where no utility power is av ailable. READ THIS MANU AL THOR OUGHL Y If you do not unde[...]

2 • Nev er star t or stop the unit with electrical loads connected to receptacles AND with connected de vices tur ned ON. Star t the engine and let it stabilize bef ore connecting electr ical loads . Disconnect all electrical loads before shutting do wn the generator . • Do not inser t objects through unit's cooling slots. • Never operat[...]

3  ELECTRICAL HAZARDS  • All generators cov ered by this manual produce dangerous electrical voltages and can cause f atal electr ical shoc k. Utility power deliv ers extremely high and dangerous v oltages as does the generator when it is in operation. Av oid contact with bare wires, terminals, connections, etc., while the unit is running. [...]

1.1 UNP A CKING • Set the palleted car ton on a rigid flat surface . • Remov e staples along bottom of car ton that fasten carton to pallet. Open car ton from top . • Remov e all packaging material. • Remo ve separate accessory box. • Lift car ton off the generator . • Remov e generator from shipping pallet by removing bolts through the[...]

5 1.2.3 B A TTER Y CONNECTION • The batter y shipped with the generator has been provided fully charged. Caution must be taken when connecting the battery . • Cut the tie wrap cable holding the RED and BLA CK batter y cab les to the stator . • Connect the RED batter y cable to the battery P ositive terminal (+). After making sure that the con[...]

6 Section 2 – Operation Commercial-Industrial-Residential P ortable Generator System OPERA TION 2.1 KNO W THE GENERA T OR Read the Owner’ s Manual and Safety Rules before operating this generator . Compare the generator to this illustration to become f amiliarized with the locations of various controls and adjustments. Sav e this manual for fut[...]

2.2 CORD SETS AND CONNECTION PLUGS 2.2.1 A C, 20 AMP , DUPLEX RECEPT A CLE This is a 120 V olt outlet protected against overload by a 20 Amp push-to- reset circuit breaker . Use each socket to po wer 120 V olt A C, single phase , 60 Hz electrical loads requir ing up to a combined 2400 w atts (2.4 kW) or 20 Amps of current. Use only high quality , w[...]

Use this receptacle to operate 120 V olt AC , 60 Hz, single phase loads requiring up to 3600 watts (3.6 kW) of power at 30 Amps . The outlet is protected by a 30 Amp push-to-reset circuit break er . 2.2.4 120/240V A C, 30 AMP RECEPT A CLE Use a NEMA L14-30 plug with this receptacle. Connect a suitable 4- wire grounded cord set to the plug and to th[...]

2.3 HO W T O USE THE GENERA T OR If you ha ve any prob lems operating your generator , please call the generator helpline at 1-800-333-1322. 2.3.1 GROUNDING THE GENERA T OR The National Electrical Code requires that the frame and external electricall y conductive par ts of this generator be properly connected to an appr oved earth ground . Local el[...]

10 2.5 W A TT A GE REFERENCE GUIDE Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Running Watts *Air Conditioner (12,000 Btu) . . . . . . . . . . . . . . . . . . . . .1700 *Air Conditioner (24,000 Btu) . . . . . . . . . . . . . . . . . . . . .3800 *Air Conditioner (40,000 Btu) . . . . . . . . . . . . . . . . . . . . .6000 Batter y [...]

11 2.6.2 ADDING GASOLINE  W ARNING: Never fill fuel tank indoor s. Never fill fuel tank when engine is running or hot. DO NO T light a cigarette or smoke when filling the fuel tank.  Caution: Do not overfill the fuel tank. Alwa ys leave room f or fuel expansion. • Use regular UNLEADED gasoline with the generator engine. Do not use premium g[...]

12 • Mo ve engine CHOKE knob to “Full Choke” position. 17 - Full Choke P osition • T o star t engine , press and hold the Star t/Run/Stop s witch in the “Star t” position. The engine will crank and attempt to star t. When the engine star ts, release the s witch to the run position. • When the engine star ts, mov e choke knob to “1/2[...]

2.12 CHARGING A B A TTER Y  D ANGER! Storage batteries give off e xplosive h ydrogen gas while recharging. An e xplosive mixture will remain around the batter y f or a long time after it has been charged. The slightest spark can ignite the hydrogen and cause an e xplosion. Such an e xplosion can shatter the batter y and cause blindness or other [...]

3.2.1 GENERA T OR SPECIFICA TIONS MODEL GPS 12500 GPS 15000 Model # 004451-1 004582-1 Rated Max. P ower 12.5 kW 15.0 kW Surge P ower 18.75 kW 22.5 kW Rated A C V oltage 120/240 120/240 Rated Max A C Load Current @ 240V 52.0 Amps 62.5 Amps Current @ 120V 104.0 Amps 125.0 Amps Rated F requency 60 Hz @3600 RPM Phase Single Phase Rated DC V oltage 12 V[...]

15 3.3 GENERAL RECOMMEND A TIONS The warranty of the gener ator does not cover items that ha ve been subjected to operator ab use or negligence. T o receive full v alue from the warranty , the operator must maintain the generator as instructed in this manual. Some adjustments will need to be made periodically to proper ly maintain the generator . A[...]

16 Use Champion RC12YC spark plug or equivalent. The correct air gap is 0.76 mm (0.030 in.). Replace the plug once each year . This will help your engine start easier and r un better . 1. Stop the engine and pull the spark plug wire off of the spar k plug. 2. Clean the area around the spark plug and remove it from the cylinder head. 3. Set the spar[...]

17 Figure 21 - Spark Arrestor 3.6 ADJUSTING V AL VE CLEARANCE After the first 50 hour s of operation, y ou should adjust the valve c learance in the engine . Important: If you f eel uncomfortable about doing this procedure or you don't ha ve the proper tools, please tak e your generator in to the nearest ser vice center to ha ve the v alve cle[...]

18 Section 3 — Maintenance Commercial-Industrial-Residential P ortable Generator System 3.7 GENERAL The generator should be star ted at least once e very sev en days and be allowed to run at least 30 minutes . If this cannot be done and you must store the unit f or more than 30 days, use the f ollowing inf or mation as a guide to prepare it f or [...]

19 4.1 TR OUBLESHOO TING Engine is running, but no A C 1. Circuit breaker is open. 1. Reset circuit breaker . output is av ailable . 2. P oor connection or defectiv e cord set. 2. Check and repair . 3. Connected de vice is bad. 3. Connect another de vice that is in good condition. 4. F ault in generator . 4. Contact A uthorized Ser vice F acility .[...]

20 Section 5 — Notes Commercial-Industrial-Residential P ortable Generator System[...]

21 Section 5 - Notes Commercial-Industrial-Residential P ortable Generator System[...]

GOVERNOR ACTUATOR 30 85 87a 86 87 GREEN WHITE Y X OFF ON J2 J1 + - 2 22 77A 66A 11 BA 44S 11S 6 44 REGULATOR VOLTAGE WHITE Y X G 30A TWISTLOK 120/240V 120V/20A HOT HOT 3 1 WHITE WHITE 5 LINE 4 LOAD 2 C.B. 30A C.B. 30A C.B. 20A C.B. 20A C.B. 30A 30A C.B. TRANSFORMERS IDLE CONTROL CONTROL ON/OFF IDLE 0 LOP FSS SP2 IM2 D IM1 SP1 D IC SSR 66 77 10A AUT[...]

23 VOLTAGE ELECTRONIC REGULATOR 11S 162 0 6 44S 4 6 5 4 3 2 1 BCR2 77A 15 66A 5 6 4 10 12 SSR 9 RESET RESET TEST TEST 18 IM2 SP2 IM1 SP1 PRINTED CIRCU IT BOARD CONTROL 12 10 11 9 2 7 8 6 4 53 J2 1 J1 15B 83 TR1 0 167 TR2 86 229 44S 11S ACTUATOR GOVERNOR 0 0 44C 22 11C 22 C.B. 0 0 0 0 22 22 22 44D 11D 44B 11B 11B 0 11A 44A 22 20A C.B. 20A 30A C.B. 3[...]

24 1 2 15 3 6 5 4 7 18 17 56 58 52 53 55 5 4 57 42 43 44 45 46 51 49 40 39 38 16 8 12 11 9 13 23 28 19 20 22 21 24 29 35 3 3 36 37 26 27 3 34 32 25 3 31 30 3 14 10 41 47 50 Section 7 — Exploded Views and P ar ts Lists Commercial-Industrial-Residential P ortable Generator System GT -990 & GT -760 Engine (Page 1) – Drawing No. 0E0034[...]

25 ITEM P ART NO . QTY . DESCRIPTION 1 0C5729 1 ASSEMBL Y , CRANKCASE HOUSING WITH SLEEVE 2 0C3008 1 SEAL, 38 I.D . CRANKSHAFT 3 090388 8 SCREW , T APTITE M6-1.0 X 12 BP 4 0C5372 1 ASSEMBL Y , BREA THER 5 0C3005 1 GASKET , BREA THER CO VER 6 0C3003 3 SEP ARA T OR, OIL BREA THER 7 0D8067A 1 ASSEMBL Y , HEAD #1 8 071983 4 RET AINER, PIST ON PIN 20 9 [...]

26 108 136 115 113 120 117 119 116 118 112 113 114 114 111 110 122 123 121 84 66 80 72 75 74 86 81 69 73 68 67 70 82 83 85 79 104 97 94 95 90 101 91 93 77 76 105 103 102 98 99 78 88 100 108 108 109 107 128 126 130 137 129 108 131 134 132 133 127 135 138 141 139 140 143 142 143 145 144 147 146 147 153 37 150 151 152 106 92 96 89 93 71 149 DETAIL &qu[...]

ITEM P ART NO . QTY . DESCRIPTION 66 087680 1 WINGNUT , AIRBO X 67 0D4511 1 PRECLEANER, AIR 68 0D3262 1 ELEMENT , AIR CLEANER 69 0D6020 1 STUD M6-1.0 X 73 70 0D4183 1 AD APT OR, SPIT BA CK 71 0D6327 1 GASKET , SPITBA CK 72 0D2774B 1 BASE, AIRBO X 73 0D5125 1 SPRING, WINTER/SUMMER VA LV E 74 0D2930 1 V AL VE, SUMMER / WINTER 75 0D4612 1 SNORKEL, AIR[...]

28 36 15 21 22 9 3 2 1 4 31 12 25 24 26 32 10 19 16 28 27 17 10 19 32 28 31 32 17 32 31 33 29 28 13 28 18 10 7 29 11 23 24 6 5 8 14 34 30 35 22 20 31 30 37 39 38 41 40 40 41 39 42 43 44 45 28 Section 7 — Exploded Views and P ar ts Lists Commercial-Industrial-Residential P ortable Generator System Generator – Drawing No. 0D4488[...]

29 ITEM P ART NO . QTY . DESCRIPTION 1 0C6934 1 ADAPT OR, ENGINE 2 0D2123 1 ST A T OR 12.5KW 0D2134 ST A TOR 15KW 3 0D2132 1 RO TOR 12.5KW 0D2133 RO T OR 15KW 4 0C6043B 1 CARRIER, REAR BEARING 5 0D2492 1 EXHAUST MANIFOLD 6 0D2726 1 MUFFLER 7 0C4138 2 GASKET , EXHA UST 8 0D3547 1 COVER, AL TERNA T OR AIR IN 9 031971 1 BEARING 10 0C3168 3 5/16 SPECIA[...]

54 54 5 5 1 1 2 2 15 15 14 14 13 13 59 59 6 6 59 59 42 42 41 41 12 12 42 42 41 41 11 11 42 42 59 59 41 41 10 10 46 46 8 8 9 9 41 41 42 42 43 43 38 38 39 39 40 40 8 8 44 44 18 18 17 17 45 45 16 16 18 18 17 17 19 19 20 20 47,48 47,48 28 28 41 41 33 33 42 42 7 7 31 31 30 30 32 32 9 9 8 8 49 49 36 36 37 37 34 34 35 35 29 29 27 27 17 17 18 18 18 18 22 2[...]

ITEM P ART NO . QTY . DESCRIPTION 1 087968 1 SWITCH, ROCKER -/0 2 090418 1 OUTLET , 12VDC SNAP 3 0D6640 1 CO VER, GO VERNOR CONTROL 4 090987 6 SCREW PPHM M3-0.5 X 12 5 0D2502 1 P ANEL, SHEET MET AL 6 068868 2 OUTLET 30A 120V RECEPT 7 022985 2 W ASHER FLA T #6 8 043182 10 W ASHER LOCK M3 9 051714 6 NUT HEX M3-0.5 G8 10 075207A 4 CIRCUIT BREAKER 30A [...]

32 22 21 26 30 28 5 6 7 8 9 15 14 32 42 24 26 27 31 51 29 5 19 18 17 20 16 10 1 37 3 4 11 12 13 33 35 7 7 6 36 34 23 39 38 41 40 39 17 2 44 43 45 46 25 17 6 7 47 48 49 50 52 7 6 36 Detail of Battery Tray POWER WIRE TO ENGINE Section 7 — Exploded Views and P ar ts Lists Commercial-Industrial-Residential P ortable Generator System Frame, Handle &am[...]

33 ITEM P ART NO . QTY . DESCRIPTION 1 057058 4 SCREW HHC M6-1.0 X 55 2 0D5315 4 R UBBER T ANK MOUNT 3 0D4570 1 CAP , FUEL WITH GA UGE & VENT 4 0D22850SR V 1 KIT , FUEL T ANK 5 045771 4 NUT HEX M8-1.25 6 022129 10 W ASHER LOCK M8-5/16 7 022145 14 W ASHER FLA T 5/16 8 0D4565 1 BRACKET BA TTER Y 9 0D3545 2 BOL T ,BA TTER Y J-BOL T 10 022287 2 SCR[...]

34 CALIFORNIA EMISSION CONTR OL W ARRANTY ST A TEMENT Y OUR W ARRANTY RIGHTS AND OBLIGA TIONS The Calif or nia Air Resources Board (CARB) and Generac P ower Systems , Inc. (Generac) are pleased to explain the Emission Control System warranty on y our new engine. In Calif or nia, ne w off-road Large Spar k-Ignition (LSI) engines m ust be designed, b[...]

35 EMISSION CONTROL SYSTEM W ARRANTY Emission Control System Warranty (ECS w arranty) for 2001 and later model y ear LSI engines: (a) Applicability: This warranty shall apply to 1995 and later model y ear engines. The ECS W arranty per iod shall begin on the date the ne w engine or equipment is purchased by/deliv ered to its or iginal, end-use purc[...]

GENERA C PO WER SYSTEMS “TWO YEAR” LIMITED W ARRANTY FOR GU ARDIAN ® “12,500 W A TT AND 15,000 W A TT POR T ABLE GENERA T ORS” F or a period of two years from the date of original sale, Generac P ow er Systems, Inc. (Generac) warrants its Guardian generator will be free from def ects in mater ials and workmanship f or the items and per iod[...]

Part No. 0E0226 06/01/02 Printed in U.S.A.[...]